Glass fiber reinforced snow ski and method of making



United States Patent [72] Inventor Leo J. Veueko Fredonia, New York [21 Appl. No. 742,781 [22] Filed July 5, 1968 [45] Patented Nov. 24, 1970 [73] Assignee Veneko Products Inc.

Jamestown, New York a corporation of New York [54] GLASS FIBER REINFORCED SNOW SKI AND METHOD OF MAKING 11 Claims, 18 Drawing Figs.

[52] U.S.Cl 280/11.13, 156/245 [51] Int. Cl A63c5/l2 [50] FieldofSearch 280/11.13; l56/(Consulted) [56] References Cited UNITED STATES PATENTS 3,145,998 8/1964 Holmberg et al .280/l l.l3(LMl 3,393,918 7/1968 280/1 1. 13(LZ) Primary Examiner-Leo Friaglia Assistant Examiner-Milton L. Smith Attorney-Donnelly, Mentag & Harrington ABSTRACT: A ski comprising a core assembly, and a top assembly and bottom assembly bonded thereto. The core assembly comprises a lightweight wood member surrounded on all sides by a waterproof plastic shell housing. The top assembly comprises an upper top layer ofcolored plastic materia1, a strip of metal edge attached adhesively along each side of the upper layer and underneath thereof, a "v shaped front metal section, and a lower layer of fiberglass-reinforced plastic. The bottom assembly comprises a bottom layer of plastic material, an L-shaped steel edge attached adhesively along each side of the bottom layer, a V"-shaped front metal section, and a top layer of fiberglass-reinforced plastic.

muted Nov. 24, 1970 Sheet of! INVENTOR. LEO J. VENEKO Q Q N E Q m Q 1mm m M 1 w Tm .EL w. ||H m AT TORNE Y5 Patented Nov. 24, 197@ 3542,3Efi

Sheet 2 of4 o i mm A /9 f j 5.5 INVENTOR.

L EO J. VENEKO ATTOPNE Y5 j 5 INVENTOR.

LEO J. VENEKO AT TORNEYS Pmmw NW. 24, ww agmma mar-5* Mum w INVENTOR. (5 LEO J. VENEKO BY ATTORNEYS GLASS FIBER REINFORCED SNOW SKI AND METHOD 7 OF MAKING This invention relates generally to improvements in the ski art, and more particularly to an improved ski construction, design and method ofmaking the same.

Heretofore, skis have been made from materials such as wood, metal and fiberglass-reinforced plastic. Some disadvantages of the prior art skis will be understood from the following discussion of such skis. Wood skis provide excellent skiing qualities, particularly their ability to flex and adjust to continuously changing terrain. (This phenomena is commonly referred to as snaking action.) Wood skis also provide excellent dampening characteristics .(the ability to absorb shock and vibration). Wood skis, however, are highly vulnerable to breakage, and they lose their camber, go flat and soften. 'At least 60 percent of the total wear on any ski occurs on the top edge of the ski. This top edge wear is due'to the constant crossing to which skis are subjected. All skis are equipped with sharp hard steel bottom edges. These edges, mounted on the bottom running surface of a ski, aid in tracking, provide bite on the snow or ice in turning, and resist wear and damage at that crucial point of the ski. This constant crossing ofthe skis, even by the so-called better skiers and experts, destroys the top part of the skis, allowing moisture to enter into the wood core member,causing warpage and camber failure. It must be understood that at least 98 percent of all ski manufacturers, of both the so-called metal or fiber glass reinforced plastic skis, utilize a wood core. in an effort to reduce the top edge wear in wood skis, some manufacturers install a top edge consisting of a strip ofplastic material. Plastic being softer than metal offers little resistance to wear due to the cutting abrasive action of the bottom steeledges. Wood skis are now considered obsolete, with the exception of inexpensive beginners, or childrens skis. Metal skis have replaced the wood skis, because of their superior wearing qualities, and their camber retention ability. Metal skis, however, provide poor skiing qualities, particularly for advanced skiers and professional skiers. Metal skis vibrate with metallic chatter at high speeds, offer poor dampening characteristics, and'they are difficult to control, particularly at the higher speeds. Metal lacks the flexural qualities of fiber glass reinforced plastic, and at the recent Olympic meet, skiers used the so-called fiberglass skis to almost the total exclusion of all others.

The prior art fiberglass skis offer some improvement over both the wood skis and the metal skis, and basically, this improvement is due to the higher degree of flexibility imparted from fiberglass-reinforced plastic material, over that of wood or metal. Fiberglass-reinforced plastic material improves the flexing action of a ski (snaking action in a ski), and provides the excellent dampening characteristics associated with wood skis. However, the prior art fiberglass skis lose their camber and go soft, and they also suffer the same poor wearability of wood skis which have top plastic edges for protection. The prior art fiberglass skis are primarily wood skis with extremely small quantities offtbergl'a'ss-reinforced plastic material. In ad dition, the prior art method of making fiberglass skis is extremely expensive, and this fact is reflected in their high cost to the consumer. in forming or assembling such aski, the various parts thereof, including the bottom assembly, the fiberglass, the core and the top fiberglass, are usually bonded and assembled in one operation, and then they are cured under heat and pressure in molds or presses. On the second day, the top edge of the ski (the top fiberglass layer) is routed to the required depth and width to accommodate the top edges, which are generally p1astic..This is an extremely expensive operation, both in regard to the type of materials used and the amount of labor required. Fiberglass is highly abrasive, and only diamond-cutting tools or routers offer the best results and performance. These top edges are adhesively bonded and retained in position by clamping, and these top edges are usually cured at room temperatures for at least 24 hours. On the third day, the top edges are sanded flush, level to the fiberglass, and finally the top plastic is adhesively bonded to the ski, and the ski is then returned to the press and cured under heat and pressure. A further disadvantage of the prior art skis, when metal top edges are used in place of plastic edges to overcome wear problems, is that loss of camber is accelerated due to problems of thermal coefficient of the various materials involved and the method of manufacture.

in view of the foregoing, it is an important object of the present invention to provide a novel ski construction and method for making the same which overcomes the aforementioned disadvantages of the prior art ski constructions and methods ofmaking the same.

It is another object of the present invention to provide a novel ski construction which is provided with a wear resistant means embedded along the top side edges thereof, to absorb the top edge wear to which skis are subjected when a pair of skis are crossed, and which function to reduce deterioration of the skis due to such top edge wear. The wear resistant means may comprise a strip of metal such as aluminum, steel, or some other suitable wear resistant material.

It is a further object of the present invention to provide a method of constructing a ski which overcomes the problem of camber loss when employing a top metal edge.

It is still another object ofthe present invention to provide a novel ski core construction and design which has a high torsional value, and which can be made with a minimum of labor and material cost.

In any fiberglass-reinforced plastic construction, the highest mechanical yield t is obtained from a lOO percent unidirectional fiberglass construction. The tensile yield can reach as high as 170,000 p.s.i. which is approximately twice the tensile yield of the best aluminum alloys found in skis ofa metal construction. A fiberglass-reinforced plastic laminate of a unidirectional construction lacks torsional rigidity. To improve the torsional values in a fiberglass-reinforced plastic construction, one must. therefore resort to a crossply or isotropic orientation of the fibers with a resulting tremendous loss in both the ultimate tensile yield and flexural modulous. Therefore, a core of this design and construction provides skis with the required high torsional value, particularly skis for advanced intermediate skiers and skis for professionals for racing in events such as the Slalom, Giant Slalom and for downhill racing. This unique type of core construction allows the full use of the high mechanical yield found in a superior unidirectional fiberglass-reinforced plastic laminate. However, even if a nonunidirectional, fiberglass construction is used, as for example, a crossply, woven fiberglass cloth, woven roving fiberglass, and other fiberglass constructions, the core of such construction and design will provide an improved ski with resulting performance, without departing from the spirit of this invention.

It is still another object of the present invention to provide an improved method for making a ski, fabricated from a plurality of materials, with aminimum number of operations, and at reduced cost, as compared to the prior art skis.

It is still a further object of the present invention to provide a novel ski which is provided with two metal plate inserts for improved wearability, with one plate mounted at the shovel end thereof and the other plate mounted at the tail end thereof.

It is stilla further object of the present invention to provide an improved method for making a ski which comprises the steps of, preforming a top subassembly, a core subassembly and a bottom subassembly, and then bonding these subassemblies together.

It is still another object of the present: invention to provide a novel and improved ski which is constructed and arranged to provide optimum dimensional stability and resistance to tor- Other objects, features and advantages of this invention will be apparent from the following detailed description, appended claims, and accompanying drawings.

in the drawings:

FIG. 1 is a side elevation view of a ski made in accordance with the principles of the present invention;

FIG. 2 is a top planview of the ski illustrated in FIG. 1, taken along the line 2-2 thereof, and looking in the direction of the arrows;

FIG. 3 is a bottom plan view of the ski illustrated in FIG. 1, taken along the line 3-3 thereof, and looking in the direction of the arrows;

FIG. 4 is an enlarged, elevational section view of the ski illustrated in FIG. 1, taken along the line 4-4 thereof, and looking in the direction of the arrows;

FIG. 5 is a fragmentary, enlarged, side elevational view of the rear end or tail of the ski illustrated in FIG. 2, taken along the line 5-5 thereof, and looking in the direction of the arrows;

FIG. 6 is a fragmentary, enlarged, horizontal section view of the structure illustrated in FIG. 5, taken along the line 6-6 thereof, and looking in the direction ofthe arrows;

FIG. 7 is a fragmentary, enlarged, side elevational view of the shovel or front end of the ski of FIG. 2, taken along the line 7-7 thereof, and looking in the direction of the arrows;

FIG. 8 is a fragmentary, horizontal section view of the structure illustrated in FIG. 7, taken along the line 8-8 thereof, and looking in the direction of the arrows;

FIG. 9 is a fragmentary, horizontal section view of the structure illustrated in FIG. 7, taken along the line 9-9 thereof, and looking in the direction of the'arrows;

FIG. 10 is a fragmentary, top plan view of the shovel end structure illustrated in FIG. 7, taken along the line 10-10 thereof, and looking in the direction ofthe arrows;

FIG. 11 is a fragmentary, elevational section view of an upper corner or side edge ofa modified ski construction;

FIG. 12 is an exploded, cross section view of the three basic subassemblies ofa ski made in accordance with the principles of the present invention, and showing the relationship of these subassemblies before they are bonded together;

FIGS. 13 and 14 illustrate in vertical cross section views the premanufactured top and bottom subassemblies of a ski made in'accordance with the principles of the present invention;

FIG. 15 is a fragmentary, vertical section view through the three subassemblies of FIG. 12, after they have been bonded together, and illustrating the process of sanding the sides of the bonded assembly;

FIG. 16 shows the further steps involved in manufacturing a ski made in accordance with the principles of the present invention, and which steps include the machining of the sides of the ski to form an offset edge on each side, the machining of the bottom groove, the routing of the top plastic corner, and the exposing ofthe top metal edge;

FIG. 17 is an enlarged, elevational section view of the tail structure of the ski illustrated in FIG. 5, taken along the line 17-17 thereof, and looking in the direction ofthe arrows; and

FIG. 18 is an enlarged, elevational section view of the shovel end structure of the ski illustrated in FIG. 7, taken along the line 18-18 thereof, and looking in the direction of the arrows.

Referring now to the drawings, and in particular to FIGS. 1, 2 and 3, the numeral 10 generally indicates the ski toe portion which is integrally formed on the front or shovel end of the ski elongated body portion that is generally indicated by the numeral 11. The numeral 12 generally designates the integral tail portion which is formed on the rear end ofthe elongated body portion 11. The toe portion 10 is approximately 8 inches long and terminates at the point indicated by the numeral 13. The tail portion 12 is approximately 2 inches long and terminates at the point indicated by the numeral 14.

Both the tail and toe portions 12 and 10, respectively, have metal inserts. The tail insert is designated in FIG. 6 by the numeral 37. The toe insert is designated in FIG. 9 by the numeral 33.

As shown in FIG. 1, the elongated body portion 11 is provided with a shape which changes throughout the length ofthe ski, both in thickness and in width. The thickest and narrowest part of the body portion 11 is at the central portion thereof which is called the waist portion, and FIG. 4 shows a cross-sectional view of the waist portion. The ski body portion 11 varies from the widest width at the front end, tapering to the narrowest width at the waist, and then widening toward the tail end. This is referred to as the side camber of the ski, as seen from the top view of FIG. 2.

It will be understood that the toe portion 10 may also be called the shovel end of the ski. The bottom camber is the built-in arc of the ski, as seen from the side view of FIG. 1, which is designed to distribute the skiers weight more evenly on the snow.

As shown in FIG. 4, the elongated body portion 11 of the ski includes a core component that comprises an elongated wood member 15 which is substantially rectangular in cross section and which is completely surrounded with a layer or shell of plastic material including the top layer 16, the bottom layer 17 and side layers 18 and 19. A suitable plastic material for forming the plastic housing or shell around the wood core member 15 is a laminated phenolic type plastic, ABS plastic, and others.

The elongated body portion 11 of the ski of the present invention further includes a bottom component including a layer of plastic material 20 which forms the bottom running surface of the ski. This bottom surface is also provided with an elongated snow groove 22, shown in FIGS. 3 and 4. The bottom component further includes a pair of bottom metal edges 23 and 24, along the outer edges of the layer of plastic material 20. The metal bottom edges 23 and 24 are L-shaped, or angle-shaped, in cross section, and they are made from any suitable metal, as stainless steel or carbon steel.

The metal edges 23 and 24 are each disposed with one of the legs thereoflocated at a bottom corner edge section of the ski, the other leg of each metal edge is attached adhesively to the inner top surface of the bottom plastic layer of material 20.

The bottom component or subassembly includes a layer of fiberglass-reinforced plastic, indicated by the numeral 25, which is disposed with the fiberglass running longitudinal of the ski and positioned between the bottom side of the core shell layer of plastic 17 and the top side of the running or bottom surface layer of 'plastic material 20. The layer of fiberglass-reinforced plastic 25 is disposed between the inwardly extended upper leg of each of the bottom metal edges 23 and 24, and it extends forward from the extreme tail end of the bottom layer of plastic 20, to the V-shaped metal insert or part 32, shown in FIG. 8, and it occupies this inner area. In addition, there are two narrow fiberglass strips, designated by the numerals 25b and 250. The fiberglass strips 25b and 250 are preimpregnated fiberglass strips in an uncured state, and they are moldable and spreadable under sufficient pressure. As well known in the fiberglass art, preimpregnated fiber glass is usually cured under heat and pressure, but it can be cured at ambient temperatures, depending upon the type of resin and catalyst used.

FIG. 12 clearly shows the location of the strips of uncured fiber glass 25b and 25c. Strip 25b is placed between the inner top leg of bottom steel edge 23 and the bottom sides of the core shell layers of plastic 17 and 18. Strip 250 is positioned between the inner top leg of bottom steel edge 24 and the bot tom sides of the core shell layers of plastic 17 and 19.

Both of the strips 25b and 250 start from the extreme end of the rear tail section 12 and are extended forward over their respective metal bottom edges 23 and 24, and over the V"- shaped metal guard 32, shown in FIG. 8. Both of the strips 25b and 250 terminate at the extreme tip or toe of the ski, at the juncture line indicated by the numeral 52 in FIG. 10. Both of the uncured fiberglass strips 25b and 250 are easily formed around the ski toe section 10, and they are cut on a bias.

The method ofthe present invention for making a fiberglass snow ski provides the advantages to be found by employing the narrow strips 25b and 25c of preimpregnated fiberglass in unidirectional high strength fiberglass-reinforced laminate is preferred. r

In the prior art fiberglass skis, the thickness of the bottom fiberglass reinforced laminate was limited to the thickness of the top upper legs of the bottom L-shaped metal edges. The thickness of the upper leg is necessarily a thin section because of the need to be flexible, and this thickness is between .025 inch to .030 inch. A fiberglass laminate of this small cross area is insufficient, and camber retention is impossible.

There is still a second method employed in the making of prior art fiberglassskis, which includes the use of neoprene rubber, wood and other materials as a spacing material between the top inner legs of the L-shaped edges. A full width fiberglass-reinforced laminate is bonded to this subbase assembly. This prior art approach results in a poor compromise. as the total parasitic mass increases proportionally to the position ofthe fiberglass.

The maximum efficiency in a ski occurs where the fiberglass-reinforced plastic laminate is located at the bottom of the ski. A ski that is being flexed places the bottom under tension and the top of the ski under compression. Unfortunately, a fiberglass-reinforced plastic laminate does not provide a proper gliding surface for a ski, suchv as polyethylene plastic with its low coefficient of friction and its absence of brittleness and minimum effect on abrasion.

A polyethylene bottom surface has little or not ability to recover on its own, as a result of flexural activity; and despite its important functional value as a bottom gliding surface, it must be considered as parasitic mass.

To advance this understanding further in reference to behavior of materials at work, total mass and the proper distribution of mass in design concept, it is only necessary to exaggerate the positioning of the bottom fiberglass-reinforced plastic laminate. By advancing it inwardly toward the neutral plane, toward the center thickness of the core member, and along this axis, this bottom fiberglass-reinforced plastic laminate would lose almost all its functional mechanical value. Therefore, to develop a ski of high flexural efficiency and to fully utilize the high strength and the freedom from fiexural fatigue and hysteresis loss, the fiberglass-reinforced plastic laminate, both in the top and bottom assemblies, must be positioned as close to the outer surface as possible to enjoy the maximum mechanical qualities of the fiberglass-reinforced plastic laminate, and to insure maximum camber retention.

It is to be further understood, that the narrow preimpregnated strips 23 and 24 are sufficiently thick, so that when pressure is created, a self-leveling effect is developed and the excess material results in a squeeze out. This method ofmanufacture of fiberglass skis reduces the number ofmanufacturing steps and minimizes the costly need for close tolerances, and the adherance to close tolerances in the preparation of parts.

The elongated body portion 11 of the ski of the present invention further includes a top assembly which is shown in FIG. 12'. FIG. 12 represents an exploded view of the various subassemblies of the ski prior to placing the ski in a press for the final cure. The top assembly comprises an upper or top layer of colored plastic material 30, which provides the necessary cosmetic finish quality to the ski. The layer of plastic 30 is quite thin, approximately 30 mills in thickness, and it may have one ofa variety ofcolors, such as black, white, red etc.

A metal strip edge is attached adhesively along each side and underneath thereof. These protective metal top edges or strips, are identified as numerals 27 and 28, and they extend from the extreme tail of the ski forward into the front toe portion and terminate respectively at the lines indicated by the numerals 34 and 35 in FIG. 10. which areapproximately 7 inches back from the extreme toe end ofthe ski.

It will be understood, the top layer of plastic 30 and the bottom layer of plastic are each preshaped as to the design dimensions of the ski and as to the length and side camber of the ski.

The core member is also premanufactured and shaped, both as to the side camber and the tapering effect and shape of the ski.

At the termination point of the top metal edges 27 and 28, at the points 34 and 35 (FIG. 10), a V"-shaped metal guard 50 is adhesively attached and forms an extension of the metal edges 27 and 28.

A layer of fiberglass-reinforced plastic laminate 26, and two uncured fiberglasss'trips 26b and 260 are employed in the top subassembly in the same manner as in the bottom sui es sembly, and they are made to the same description and dimen- SIOllS.

FIG. 11 shows a slight modification in which the top layer of plastic 30 has been slightly sanded along the outer edges thereof to provide a minimal metal exposure along the longitudinal corners or edges of the ski. FIG. 4, however, shows the top edge as viewed from the top, considerably exposed mainly for cosmetic effect, which is accomplished by a routing operation as shown in FIG. 16 and as carried out by a conventional routing tool 47..

A suitable wood for the core member 15 is a lightweight wood such as red cedar.

As shown in FIG. 7, the bottom metal edge 24, and also the metal edge 23, extends forward into the toe portion 10 and terminates at the point indicated by the numeral 31. A V- shaped metal guard strip is disposed in the front end of the toe portion 10, and it is indicated by the numeral 32, in FIGS. 7 and 8. As seen in FIG. 8, the V-shaped metal guard strip 32 forms an extension of the bottom metal edges 23 and 24.

As shown in FIG. 7, the base or bottom surface plastic layer 20 is extended throughout the toe portion 10 of the ski up to the front end thereof, and it extends for the entire bottom length ofthe ski.

As shown in FIGS. 7, 9 and 18, the toe portion It) is provided with a metal plate 33 which is spaced apart upwardly from the bottom metal edges 23 and 24 and sandwiched between the bottom fiberglass-reinforced plastic laminate layer 25 and the fiberglass strips 25b and 250.

As further shown in FIG. 7 and as will be understood from FIG. 12, the metal plate 33 also seats against the top layer of fiberglass 30 and the uncured fiberglass strips 26b and 26c.

shown in FIG. 6, the ski tail portion 12 is provided with internal metal plate 37 which has its front end 38 adjacent the rear end 39 ofthe core component wood member 15. The rear end 40 of the metal plate 37 terminates at the tail end of the ski. The plate 37 is also sandwiched and adhesively bonded between the upper and lower laminates of fiberglass-reinforced plastic; that is, between elements 25, 25b and 25c, and 26, 26b and 260. The core member 15 extends for the entire length of the body portion 11 and abuts the front and rear plates 33 and 37, respectively.

The aforementioned top component, core component, and bottom components of the elongated body portion 11 are preformed as separate subassemblies or components, and then bonded together in a single operation with the additional elements to form the toe portion 10 and the heel portion 12.

As shown in FIG. 5 and 17, the outer side edges of the metal plate 37 are exposed and function as a guide means. The plate 37 improves wearability in the ski tail area. This is also true of the metal plate 33 for the ski toe area. As also shown in FIG. 5, the top plastic layer 30 is extended over the heel or tail portion 12 of the ski and over the entire length of the ski. The ground bottom metal edges 23 and 24 are also extended under the heel portion 12 and they terminate at the tail end ofthe ski. As shown in FIG. 5 and 6, the heel portion 12 is provided with a suitable metal heel guard 41 which may be secured to the ski by any suitable means as by screws.

As shown in FIG. 4. the ski is provided on each side thereof with an offset, or longitudinal projection, as shown by the numeral 42 and 43, which are formed on the ski, after the bonding together ofthe subasscmblies, by shaping the side surfaces thereof on a high speed router or shaper 45, shown in FIG. I6. A second suitable router or shaper 46 is also shown in FIG. 16 for forming the longitudinal snow groove 22 in the bottom ground engaging layer ofplastic 20.

FIG. 15 indicates the step of sanding the sides of the ski by means of a suitable sanding apparatus 44 to remove any overflow of plastic, as 48, from the sides ofthe ski.

FIG. 13 shows the premanufactured top assembly at a stage wherein the plastic top layer 30, the top metal edges 27 and 28, the V-shaped metal guard 50, and the cured fiberglassreinforced plastic laminate 26, are all bonded together as an integral unit to formthe top assembly.

FIG. 14 shows the premanufactured bottom subassembly in a stage wherein the bottom layer of plastic 20, the metal bottom edges 23 and 24, the V-shaped metal guard 32 (as shown in FIG. 8), and the cured fiberglass-reinforced .plastic laminate 25 have been assembled and bonded together as an integral unit to form the bottom assembly prior to the final assembly of the ski. I

The assemblies of FIGS. 13 and 14 are bonded and cured at elevated temperatures with a high heat distortion adhesive, such as an'Epoxy adhesive. 7

In the step of making the top and bottom assemblies, the high heat distortion adhesive secures the top metal edge strips 27 and 28 to the plastic top layers 26 and 30, and the bottom metal edge strips 23 and 24 to the plastic bottom layers and 25. A heat distortion adhesive such as an Epoxy adhesive with a heat distortion of 275 to 300F. is required.

Upon final assembly into the final ski, a lower heat distortion adhesive is used, having a heat distortion of approximately 200F., so as not to injuriously affect the previous bond. During this final cure the metal edges are securely contained against movement and thermal expansion, minimizing the higher coefficient of expansion of the metal edges, as opposed to the lower coefficient of both the fiberglass and the plastic top material, and minimizing the adverse effect of camber loss when using top metal edges in a fiberglass ski.

The following is a description of a typical assembly of a ski made in accordance with the principles of the present invention. The bottom subassembly is introduced into a ski press or mold, and to this bottom subassembly is added the two narrow strips of fiberglass 25b and 250. The tail or heel end metal insert 37, as illustrated in FIG. 6, is then inserted in place in the mold on the bottom subassembly. The core portion of the ski is then disposed in place in the mold in a position abutting the rear insert plate 37. The shovel or toe plate 33, shown in FIG. 9, is then disposed in place in the mold. The premanufactured top subassembly is then disposed in place in the mold. The last-mentioned action is carried out by first laying the top subassembly on a tablewith the bottom side up. The two narrow fiberglass strips 26b and 260 are then introduced into their positions. A plurality ofsmall spring clamps temporarily fasten the fiberglass strips 26b and 260 to the top subassembly. The top subassembly is then inserted into the mold and the spring clamps removed. The male members of the mold are then pressed with the required pressure to complete the assembly ofthe various ski subassemblies into a unified ski structure.

While it will be apparent that the preferred embodiments of the invention herein disclosed are well calculated to fulfill the objects above stated, it will be appreciated that the invention issusceptible to modification, variation and change without departing from the proper scope or fair meaning of the subjoined claims.

Iclaim: l. A ski comprising: a. an elongated body portion; b. a toe portion; c. a tail portion; d. said elongated body portion including a bonded assembly of, l. a core component; 2. a top component; and 3. a bottom component; e. said core component comprising an elongated wood member which extends throughout the entire length of the body portion and abuts the toe and tail portions, and a plastic material shell completely surrounding the clongated wood member; f. said top component comprising a layer of plastic material adhesively bonded to unidirectional fiberglass and disposed on the top side of the core component and extended longitudinally of the entire length of the ski, an protective guard strip of metal disposed along each of the upper outer edges of said layer of plastic material adhesively bonded to fiberglass, and, at least one layer of plastic material disposed on the top side of said layer of plastic material impregnated with fiberglass and having the outer side edges thereof terminating in a manner so as to expose at least the outer edges of said metal guard strips so as to provide a scuffing metal guard area along the upper edges of the body portion of the ski;

g. said bottom component comprising a layer of plastic material forming the ground-engaging surface of the ski, a ground-engaging guard strip of metal disposed along each of the outer edges of said last mentioned layer of plastic material, and, a layer of plastic material impregnated with unidirectional fiberglass disposed longitudinally of the ski and positioned between the bottom side ofsaid core component and said last mentioned layer of plastic material and metal guard strips;

h. said toe portion being provided with an internal metal plate which has its back end abutting-the front end of the core wood member and its front end terminating at the pointed front end of the ski;

i. said ground-engaging metal strips on the ski body portion being extended throughout the greater portion of the length of the toe portion and terminating at a point spaced apart from the pointed end of the toe portion; and

' j. said toe portion being provided with an integral, substantially V-shaped metal guard strip in the forward end thereof which is aligned with the upper part of the ground engaging metal strips and disposed on the top side of the ground engaging layer of plastic material of the bottom component.

2. A ski as defined in claim 1 wherein:

a. said tail portion is provided with an internal metal plate which has its front end abutting the back end of the core wood member and its back end terminating at the rear end ofthe ski; and

b. said scuffing guard metal strips and ground engaging metal strips on the ski body portion are extended throughout the length of the tail portion and terminate at the rear end ofthe ski.

3. A ski as defined in claim 1, wherein: said ground-engaging metal strips are angle-shaped in cross section and are disposed with one of the legs ofthe angle shape parallel to the respective side of the ski on which it is disposed, with the lower end of the last-mentioned leg aligned with the ground engaging surface of the bottom component for engagement with the ground.

4. A ski as defined in claim 1 wherein: a strip of fiber glass is mounted between each of the scuffing guard metal strips and the core component, and, between each of the ground-engaging metal guard strips and the core component.

5. A ski comprising:

a. an elongated body portion;

b. a toe portion;

c. a tail portion;

d. said elongated body portion including a bonded assembly I. a core component;

2. a top component; and 3. a bottom component;

c. said core component comprising an elongated wood member which extends throughout the entire length of the body portion and abuts the toe and tail portions, and a plastic material shell completely surrounding the elongated wood member;

. said top component comprising a layer of plastic material adhesively bonded to unidirectional fiberglass and disposed on the top side of the core component and extended longitudinally ofthe entire length ofthe ski, a protective guard strip of metal disposed along each of the upper outer edges of said layer of plastic material adhesively bonded tofiberglass, and, at least one layer of plastic material disposed on the top side of said layer of plastic material impregnated with fiberglass and having the outer side'edges thereof terminating in a manner so as to expose at least the outer edges of said metal guard strips so as to provide a scuffing metal guard area alon the upper edges of the body portion of the ski;

said scuffing guard metal strips on the ski body portion being extended throughout the greater portion of the length of the toe portion and terminating at a point spaced apart from the pointed end of the toe portion; and

h. said toe portion being provided with an integral, substantially V-shaped m'etal guard strip in the forward end thereof which is aligned with the scuffing guard metal strips and disposed beneath the top layer of plastic material of the top component.

6. A method of making a ski comprising the steps of:

a. forming a core component by providing an elongated wood member having an overall shape in thickness and length corresponding to the shape of a body portion of a ski, and bonding a plastic material completely around said wood member;

b. forming a top component by providing a layer of plastic material bonded to unidirectional,fiberglass having an overall shape in plan corresponding to the shape of a ski having a body portion, a toe portion and tail portion, disposing a scuffing guard metal strip along each of the upper outer edges of said layer of plastic material, with the metal strips extending fromthe rear end of the tail portion forwardly over the body portion and partially over the toe portion, disposing a V-shaped metal guard under said layer of plastic material at the front end of the toe portion thereof and at the front end of said metal strips, disposing alayer of decorative plastic material over the upper surface .of said layer of plastic material impregnated with fiberglass and over said metal strips and V-shaped metal guard, and bonding said layers of plastic material, metal guard strips and V-shaped metal guard together; r

. forming a bottom component by providing a first layer of plastic material having an overall shape in plan corresponding to the shape of a ski having a body portion, a toe portion, and a tail portion to form a ground-engaging surface for the ski, disposing a ground-engaging guard metal strip along each of the outer edges of said first layer of plastic material, with the metal strips extending from the rear end of the tail portion forwardly over the body portion and partially'over the toe portion, disposing a V- shaped metal guard on top of said first layer of plastic material at the front end of the toe portion thereof and at the front end of said metal strips, disposing a second layer of plastic material impregnated with fiberglass over said first layer of plastic material, and] bonding said layers of plastic material, metal guard strips, and V-shaped metal guard together; I

d. providing a ski-shaped mold;

e. disposing the bottom, core and top components in said mold;

f. mounting a toe metal plate between the front ends of the toe portions-of said top and bottom components, and a tail metal plate between the rear ends of the tail portions of said top and bottom components; and

g. bonding the bottom, core and top Components. and toe Y and tail plates together by heat and pressure into a com posite ski structure.

7. A method of making a ski as defined in claim 6, wherein: the layer of plastic material impregnated with fiberglass for each of the top and bottom components is formed from, a layer of cured fiberglass and plastic which is disposed between themetal guard strips, and a strip of uncured fiberglass and plastic material disposed over each of said metal guards of a thickness greater than the thickness of said last mentioned layer of cured fiberglass and lastic material.

8. A method of making a s l as defined in claim 6, including:

sanding the sides of the composite ski structure.

9. A method of making a ski as defined in claim 8, including: routing the side surfaces of the composite ski structure to form a longitudinally extending offset along the lower outer edges of the ski.

10. A method of making a ski as defined in claim 8, including: routing a longitudinal snow groove along the bottom surface of the ski.

11. A method of making a ski a s defined in claim 8, including: routing off the top layer of decorative plastic mate rial along the upper outer top edges of the ski to expose the outer portion of the upper surfaces of the metal guard edge strips. 

